1999 LAND ROVER DEFENDER air filter

LUBRICANTS, FLUIDS AND CAPACITIES
3
INFORMATION CAPACITIES
The following capacity figures are approximate and are provided as a guide only.
Capacities (approx.)* Litres Pints
Engine sump oil - Td5 7.20...................................................... 12.67
Extra when refilling after fitting new filter 1.00.......................... 1.76
Manual gearbox 2.38............................................................... 4.19
Transfer gearbox oil 2.30......................................................... 4.00
Front differential 1.70............................................................... 3.00
Rear differential
90 Models 1.70............................................................... 3.00
110 Models 2.26............................................................. 4.00
Power steering box and reservoir LHD 2.90............................ 5.00
Power steering box and reservoir RHD 3.40............................ 6.00
Swivel pin housing oil/grease (each) 0.35................................ 0.60
Fuel tank usable fuel
90 Models 60.00............................................................... 13.20 gall
110 & 130 Models 75.00................................................... 16.50 gall
Cooling system - Td5 13.00....................................................... 22.88
Washer bottle 3,0................................................................... 5.28
NOTE: * All levels must be checked by dipstick or level plugs as applicable.
ANTI-FREEZE
PERCENTAGE CONCENTRATION - 50%
PROTECTION - LOWER TEMPERATURE LIMIT
Complete protection
Vehicle may be driven away immediately from cold,
-33°C (-36°F).
Safe limit protection
Coolant in semi-frozen state. Engine may be started
and driven away after warm-up period, -41°C (-42°
F).
Lower protection
Prevents frost damage to cylinder head, block and
radiator. Thaw out before starting engine, -47°C (-53°
F).
CAUTION: Anti-freeze content must never
be allowed to fall below 50% otherwise
damage to the engine is liable to occur.
Also, anti-freeze content should not exceed 60%
as this will greatly reduce the cooling effect of the
coolant.RECOMMENDED FUEL
Diesel fuel oil, distillate, diesel fuel, automotive gas or
Derv to British standard 2869, Class A1 or A2
Using diesel fuel with a class rating lower than stated
above could seriously impair vehicle performance.
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10 - MAINTENANCE
CONTENTS
Page
MAINTENANCE
UNDERBONNET VIEW - Td5 1..............................................................................
SEATS AND SEAT BELTS 2..................................................................................
LAMPS, HORNS AND WARNING INDICATORS 2................................................
WIPERS AND WASHERS 3...................................................................................
HANDBRAKE 3.......................................................................................................
BATTERY CONDITION - Td5 4..............................................................................
HANDSET BATTERY 5...........................................................................................
HEADLAMP ALIGNMENT 5....................................................................................
ROAD WHEELS 6...................................................................................................
TYRE PRESSURES, CONDITION AND TREAD DEPTH 6....................................
BRAKE PADS, CALIPERS AND DISCS 7..............................................................
ROAD WHEEL SPEED SENSOR HARNESS - Td5 7............................................
FUEL FILTER ELEMENT 8.....................................................................................
FUEL FILTER SEDIMENTER - Td5 8.....................................................................
INTERCOOLER / COOLING SYSTEM 9................................................................
AMBIENT AIR PRESSURE (AAP) SENSOR - Td5 9..............................................
DOOR LOCKS AND HINGES 10............................................................................
ENGINE COOLANT 10...........................................................................................
BRAKE FLUID 11....................................................................................................
AIR FILTER ELEMENT AND DUMP VALVE 11.....................................................
AUXILIARY DRIVE BELT 12...................................................................................
PAS FLUID, CLUTCH FLUID AND SCREEN WASHER LEVELS 12.....................
STEERING BOX 13................................................................................................
ENGINE OIL 14.......................................................................................................
CENTRIFUGE ROTOR - Td5 14.............................................................................
FULL FLOW OIL FILTER 15...................................................................................
GEARBOX OIL 15...................................................................................................
TRANSFER BOX OIL 16.........................................................................................
FRONT AND REAR AXLE OIL 17..........................................................................
PROPELLER SHAFTS 18.......................................................................................
CLUTCH PIPES AND UNIONS 18..........................................................................
PAS PIPES AND UNIONS 19.................................................................................
ENGINE, GEARBOX, TRANSFER BOX AND AXLES 19.......................................
EXHAUST SYSTEM 20...........................................................................................
STEERING BOX AND SUSPENSION 20...............................................................
STEERING BALL JOINTS 21.................................................................................
SHOCK ABSORBERS 22.......................................................................................
TOWING BRACKET 22...........................................................................................
ENGINE AND TRANSMISSION MOUNTINGS 23..................................................
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10MAINTENANCE
8
MAINTENANCE FUEL FILTER ELEMENT
1.Renew fuel filter element.See FUEL SYSTEM,
Repair.FUEL FILTER SEDIMENTER - Td5
WARNING: Fuel vapour is highly
flammable and in contained speces is also
explosive and toxic. Always have a fire
extinguisher containing FOAM, CO2, GAS OR
POWDER close at hand when handling or draining
fuel.
1.Disconnect battery negative lead.
2.Position suitable container beneath fuel filter
3.Disconnect multiplug from sedimenter
4.Rotate sedimenter anti-clockwise until water
flows from drain tube.
5.Allow to drain until diesel fuel flows from drain
tube.
6.Rotate sedimenter fully clockwise.
7.Connect multiplug.
8.Reconnect battery negative lead.
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MAINTENANCE
11
MAINTENANCE BRAKE FLUID
1.Renew brake fluid.See BRAKES,
Adjustment.AIR FILTER ELEMENT AND DUMP VALVE
1.Replace air cleaner element.See FUEL
SYSTEM, Repair.
2.Remove all dirt from dump valve.
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MAINTENANCE
15
MAINTENANCE FULL FLOW OIL FILTER
1.Renew full flow oil filter.See ENGINE , Repair.GEARBOX OIL
WARNING: Avoid excessive skin contact
with used gearbox oil. Used gearbox oil
contains potentially harmful contaminants
which may cause skin cancer or other serious
skin disorders.
1.Renew gearbox oil.See MANUAL GEARBOX,
Adjustment.
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12 - ENGINE
CONTENTS
Page
DESCRIPTION AND OPERATION
TD5 ENGINE 1........................................................................................................
GENERAL 12..........................................................................................................
CYLINDER BLOCK 13............................................................................................
CRANKSHAFT, SUMP AND OIL PUMP 22............................................................
CYLINDER HEAD COMPONENTS 25...................................................................
CAMSHAFT COVER COMPONENTS 30...............................................................
CAMSHAFT TIMING CHAIN COMPONENTS 30...................................................
CYLINDER BLOCK FLOW 32.................................................................................
OIL COOLER / FILTER FLOW 34...........................................................................
CYLINDER HEAD FLOW 36...................................................................................
ADJUSTMENT
ENGINE OIL PRESSURE CHECK 1......................................................................
REPAIR
CAMSHAFT 1.........................................................................................................
PULLEY - CRANKSHAFT 3....................................................................................
OIL SEAL - CRANKSHAFT - REAR 4.....................................................................
BEARING - SPIGOT - CRANKSHAFT 5.................................................................
GASKET - CYLINDER HEAD 6..............................................................................
ROCKER SHAFT ASSEMBLY 11...........................................................................
GASKET - COVER - CAMSHAFT 13......................................................................
ENGINE AND ANCILLARIES 14.............................................................................
MOUNTING - FRONT - LH 19................................................................................
MOUNTING - FRONT - RH 20................................................................................
MOUNTING - GEARBOX - REAR - LH 21..............................................................
MOUNTING - GEARBOX - REAR - RH 22.............................................................
FLYWHEEL 22........................................................................................................
FILTER - OIL 23......................................................................................................
STRAINER - OIL PICK-UP 24.................................................................................
PUMP - OIL 24........................................................................................................
GASKET - ENGINE TO SUMP 26..........................................................................
SWITCH - OIL PRESSURE 28...............................................................................
VALVE - RELIEF - OIL PRESSURE 29..................................................................
COOLER - ENGINE OIL 29....................................................................................
CENTRIFUGE ASSEMBLY 30................................................................................
ROTOR - CENTRIFUGE 32....................................................................................
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12ENGINE
12
DESCRIPTION AND OPERATION GENERAL
The Td5 diesel engine is a 2.5 litre, 5 cylinder, in-line direct injection unit having 2 valves per cylinder, operated by
a single overhead camshaft. The engine emissions on pre EU3 models comply with ECD2 (European Commission
Directive) legislative requirements. EU3 models comply with ECD3 legislative requirements. Both units employ
electronic engine management control, positive crankcase ventilation and exhaust gas recirculation to limit the
emission of pollutants. The unit is water cooled and turbo-charged and is controlled by an electronic engine
management system.
The cylinder block is a monobloc cast iron construction with an aluminium stiffening plate fitted to the bottom of the
cylinder block to improve lower structure rigidity. The cylinder head and sump are cast aluminium. An acoustic
cover is fitted over the upper engine to reduce engine generated noise.
The engine utilises the following features:
Electronic Unit Injectors (EUI’s)controlled by an Engine Management System for precise fuel delivery under
all prevailing operating conditions.
Turbochargingwhich delivers compressed air to the combustion chambers via an intercooler for improved
power output.
Fuel Cooler
Oil Cooler
Centrifuge Oil Filter
Hydraulic Lash Adjusterswith independent finger followers
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12ENGINE
6
REPAIR GASKET - CYLINDER HEAD
Service repair no - 12.29.02
Remove
NOTE: The following procedures cover
engines fitted with or without an EGR
cooler. The EGR cooler is bolted to the
front of the cylinder head.
1.Remove underbelly panel.See CHASSIS AND
BODY, Repair.
2.Drain cooling system.See COOLING
SYSTEM, Adjustment.
3.Remove camshaft cover gasket.See this
Section.
4.Remove cooling fan.See COOLING SYSTEM,
Repair.
5.Release clips and disconnect air flow meter from
air filter.
6.Disconnect multiplug from air flow meter.
7.Loosen clip and remove air inlet hose from
turbocharger.
8.Remove 3 bolts and remove exhaust manifold
heat shield.
9.Remove turbocharger oil feed banjo bolt and
discard sealing washers.
10.Remove 3 nuts, release turbocharger from
exhaust manifold, discard gasket and tie
turbocharger aside.
11.Remove 2 bolts securing engine harness to
camshaft carrier.
12.Disconnect fuel injector, coolant and compressor
sensors.
13.Disconnect 4 heater plug connectors.
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